Title: Experimental analysis and optimisation of process parameters for gear cutting process using wire EDM

Authors: Kasinath Das Mohapatra; Susanta Kumar Sahoo

Addresses: Department of Mechanical Engineering, National Institute of Technology Rourkela, Odisha, India ' Department of Mechanical Engineering, National Institute of Technology Rourkela, Odisha, India

Abstract: Wire EDM is a non-traditional machining operation in which complicated profiles are cut by the help of a wire by the application of heat produced from the electrical sparks. Gear cutting is a challenging task in which small teeth are cut by the help of wire for the manufacturing of gears to meet the growing demand. The objective of the present work is to minimise the error present in the gears by optimising the input parameters to get the optimum value. The proposed work deals with the analysis and optimisation of response parameters, i.e., single pitch error and material removal rate of wire electric discharge machined spur gears made of copper material. The values of pitch error and MRR of the gear obtained by these experiments were optimised and a loss function is generated by optimising the single pitch error and MRR. The loss function is investigated and the optimum value obtained can be applied for future findings.

Keywords: face width; material removal rate; MRR; single pitch error; pulse on time; pulse off time; spur gears; wire feed rate; wire tension; wire EDM; optimisation; gear cutting; electrical discharge machining; electro-discharge machining; loss function; copper.

DOI: 10.1504/IJMMS.2016.082863

International Journal of Mechatronics and Manufacturing Systems, 2016 Vol.9 No.4, pp.327 - 344

Received: 28 Jul 2015
Accepted: 22 Mar 2016
Published online: 14 Mar 2017 *

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